In traditional gear forging workshops, manual handling, manual lubrication, and unstable production cycles often limit productivity and quality consistency. In addition, high-temperature manual operations increase safety risks.

As industries such as automotive and construction machinery demand higher gear precision and stable mass production, gear forging automation is no longer an option—it is a necessity.

A typical automated gear forging line is integrated by below forging systems:

• Automatic bar handling and positioning
• Induction heating with temperature control
• Six-axis robotic transfer
• Automatic graphite spraying
• Pre-forging and final forging
• Automatic trimming and unloading

With the deep integration of robots and automation systems, each process step operates under consistent and repeatable conditions. A six-axis forging robot, for example, can flexibly handle hot billets across multiple stations with stable cycle times and high repeatability, significantly reducing dependence on manual labor.

At the same time, the automatic graphite spraying lubrication system atomizes the graphite lubricant evenly and carefully through efficient atomization technology, and lubricates the die cavity accurately and evenly before each forging, focusing on the tooth root and fillet area, which can not only effectively reduce the graphite consumption but also significantly prolong the die life.

In practical applications, automated gear forging systems could bring customers achieve a lot of advantages including below:

• Greatly reduce labor cost
• Effectively increase in die life
• Significantly improve product consistency and stability
• Reliable 24/7 production capability

It can be seen that automation is not only an equipment upgrade, but also a strategic investment and systematic equipment to turn unstable manual processes into controllable and repeatable production processes that enables gear manufacturers to build long-term competitiveness in quality, cost control, and delivery performance.